CA1260350A - Process and apparatus for providing roll reconstituted tobacco material - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A process for reclaiming tobacco comprises providing tobacco material including relatively large fibrous forming tobacco leaf stem material, passing the tobacco through a pressurized roller system, and forming a reclaimed tobacco material under pressure.
Tobacco stems, fines, dust and waste can be reconstituted in sheet-like form using a process which utilizes relatively low amounts of moisture.

Description

r~350 PROCESS AND APPARATUS FOR PROVIDING
~LL REC~ISTIT[ITED TOBACC~ MATERIAL

~CKG~nU~I~ OF THE INVE~TI~J

This invention re].ates to methods for making tobacco products, and in particular, to methods for maki.ng recorstituted tobacco products under conditions of relatively low moisture le~7el.s.
~ hen tobacco leaf is processed for use in smokin~
products and when tobacco products are manufactured. a substantia]. amount of scrap or wast0 tobacco is provided. ScraP or waste tobacco can be in the form of tobacco dust (typical particle size ;.s less than about 60 Tyl.er mesh), tohacco fines (typical ~article size is between about 20 Tyler mesh and about 60 Tyler mesh), tobacco stems. or processed tobacco which remains unused after tobacco product manufacture is interrupted : or completed. As scrap or waste tobacco frequently is of high ~uality, it is highly desirable to reclaim or reconstitute such scrap or waste tobacco~ For example, it is desirable to provide reclaimed or reconstituted tobacco in sheet form, an~ to blend the reclaimed or reconstituted tobacco with tobacco leaf in order to provide cut filler. The resulting cut filler ;s used in the manufacture of cigarettes.

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Various methods for providing reclaimed, r~formed, reassembled or reconstituted tobacco are known. For example, tobacco mat,erials can he mixed with relati,vely large amounts of water, processed, and dried. U. ,S.
Patent Mo. ],06~,403 discloses a process for the pro-duction of so-called artificial tobacco leaves by which tobacco veins are mixed with water in order to form a pulp, and the pulped veins are further processed.
However, the method disclosed in U~ S. Patent No~
1,n68,ao3 reauires the use of relatively large amounts of water and undesirabl.e subsequent drying steps~
U~ S. Patent r~O. 3,053,259, di.scloses another method for reclaiming tobacco fragments or tobacco fines. For example, tobacco material 1s qround to a very .small size using a hammer mill or ball mill the ground tobacco is moistened or mixed wi.th a binder; and filamentary shreds are press formed or molded by passing the resulting mixture between a smooth surface roller and a grooved roller. However, the disclosed method reauires the use of relati.vely large amounts of moisture, especially when a binder i.s not employed.
As there is a need for a process for regenerating tobacco waste products, it would be highly desirahl~ to provide an efficj.ent and effective process for providing reclaimed tobacco in the form of a sheetA In particu.lar, it is desirable to provide reclai.med tobacco using a process which requires neither the use of a relatively large amount of water and post dryi.ng ! of product nor the pre-grinding of tobacco material.

k~3 5~
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~ M~1~RY OF TE~E INVEl`lTIOM

: This i.nvention is a process for providing reclaimed tobacco material in sheet-like for~, said process comprising the steps in combination (a) providing tobacco material including tobacco ~eaf stem material, the tohacco material having a moisture content ]ess than about 30 weight percent, and then (h) passing the tohacco material through the nip of a first ~ressurized roller system having two rollers exhibiting a nip zone pressure sufficient to provlde compression of said tobacco material thereby providing compressed, admixed tobacco material, wherein at least one of the roller faces comprises a series of grooves which ser;es extends longitudinally along the roller and each aroove extends about the periphery of the ro].ler, wherein each groove has a maxi.mum width near the surface of the roller and a minimum width near the bottom of the groove, wherein each of the grooves has a maximum width and depth which is smaller than the l.ength and~or diameter of tobacco leaf stem material, and wherei.n the tobacco leaf stem material is employed in a structural strength providing amount, and then (c) forming under pressure reclai.med tobacco material in sheet-like form by passing the compressed, admi.xed tobacco material through the nip of a second pressuri~ed roller system having two rol.lers exhibi.ting a nip zone pressure sufficient to provide the reclaimed tobacco material, wherein the roller faces of the rollers are positioned in a spaced apart relationship in the region along the rollers where the reclaimed tobacco material is formed, and wherein the spaced apart relationship between the 1_161 :3 12&~ 5~

faces of the ro].lers pro~7ides a sufficient distan~e therebetween to provide formed sheet-like reclai,med tobacco material.
J.n another aspect, this invention is an ap~aratus for provi.ding reclaimed tobacco, the apparatus com-prising (a) a first pressurized roller system wherein at least one of the roller faces thereof compri.ses a series of grooves, which series extends longitudinally along the roller wherein each groove extends about the periphery of the ro],ler, and wherein each groove has a maximum width near the surface of the roller and a minimum width near the bottom of the groove, (b) a second pressurized roller system wherein the roller faces of the rollers are positioned in a spaced apart rel.ationship in a region along the rollers, and wherein the spaced apart. relationship between the faces of the rollers is a distance which approximates the thickness of sheet-l.ke reclaimed tobacco material.
Tn another aspect, this invention is a process for providing reclaimed tobacco material in sheet-J.ike form, said process comprising the steps in comhination (a) providinq tobacco material including tobacco leaf stem material, the tobacco mat,erial having a moist.ure content ].ess than about 3n weight percent, and then (b) passing the tobacco material through the nip of a pressurized roller system having two rollers exhibiting a n;,p zone pressure sufficient to provide compression of said tobacco material thereby providing said sheet-like material, wherein (i) at least one of the roller faces comprises a series of grooves, which series extends longitudinally along the roller and each groove extends about the periphery of the roller, wherein each groove has a maximum width near the surface o the roller and a minimum width near the bottom of the .
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groove, wherein each o the arooves has a max;mu~ width and depth ~hich is smaller than the length and/or diameter of tobacco leaf stem material, and wherein the tobacco leaf stem material is employed in a structured strength providing amount and (ii) wherein the roller faces of the rol].ers are in a spaced apart relationship in the region along the rollers where the reclai.meA
tobacco material is formed and wherein the spaced apart relationship between the faces of t,he rollers provides a sufficient distance therebetween to provide formed sheet-like reclaimed tobacco material.
In another aspect, this invention is a,n apparatus for provi.ding reclaimed tobacco, the apparatus com-prising (a) a pressurized roller system wherein at least one of the roller faces compri.ses a series of grooves, which series extends longitudinally along the roller and each groove extends about the periphery of the roller, wherein each groo~7e has a maximum width near the surface of the roll.er and a mi.ni.mum width near the bottom of the groove, wherein each of the qrooves has a maximum width and depth which is smaller t.han the : length and/or di.ameter of tobacco leaf stem materia], and wherei,n the roller faces of the rollers are in a spaced apart relati.onship in a region along the ro].lers where the reclaimed tobacco materia]. is formed and wherein the spaced apart relationship between the faces of the rollers is a distance which approximates the thickness of sheet-like reclaimed tobacco ~aterial.
;Surprisingly, the invention allows for the reclamation of tobacco in an effi.cient and effective manner usin~ a process which reaui.res neither relatively large amounts of moisture nor the necessity of the addition of b;.nders. In fact, the process of this invention can he performed in the absence of T-161~5 35~

binders. However, the process can be performed using binders, humectant, and/or other additives, if desired. The process of this invention can be performed using relatively large pieces of tobacco leaf and leaf stem material, and does not require the pre-grinding of said stem material to a small size. The pr~cess of this in-vention can be performed at or near ambient temperatures without the necessity of the application of external heat. If desired, the process of this invention can be performed without chemical pretreatment of the tobacco.
The reclaimed tobacco material in sheet-like form can be employed as is known in the art. For example, the tobacco mater-ial provided by the process of this invention can be dried or moistened, cut to the desired size, treated with additives, blend-ed with other tobacco products, etc. The resulting reclaimed tobacco material is most useful in the manufacture of cigarettes.
Thus, this invention includes a cigarette containing the reclaimed tobacco material prepared according to the process of this inven-tion.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a diagrammatic illustration of one embodi-ment of an apparatus and process of this invention showing the two pressurized roller systems and tobacco material processed to reclaimed sheet-like material;
Figure 2, on the second page of the drawings, is a perspective of an apparatus of this invention showing the pressur-ized roller system;
Figure 3, on the first page of the drawings, is an en-35~

larged, partial sectional view of a roller taken along line 3-3 in Figure 1 and showing a series of grooves, each groove extending circumferentially about the periphery of the roller;
Figure 4 is an enlarged diagrammatic illustration taken : transversely to the longitudinal axis of the rollers and showing the longitudinal lengths of two rollers forming one pressurized ; roller system illustrated in Figures 1 and 2;
Figure 5 is an enlarged, partial sectional view of one embodiment of a roller taken along line 5-5 in Figure 1 showing the depressed groove extending longitudinally along the roll face of the roller and therewithin a series of grooves, each groove extending circumferentially about the periphery of the roller;
Figure 6 is an enlarged partial sectional view of one embodiment of a roller taken along line 5-5 in Figure 1 showing the depressed groove extending longitudinally along the roll face of the roller;
Figure 7 is an enlarged, partial sectional view of one embodiment of a roller taken along line 5-5 in Figure 1 and showing : the depressed groove extending longitudinally along the roll face of the roller and therewithin an uneven groove surface;
Figure 8 is an enlarged, partial sectional view of one embodiment of two rollers forming the second pressurized roller system shown along the line of roll contact of the rollers and taken along line 8-8 in Figure l;
Figure 9 is an enlarged, partial sectional view of one embodiment of two rollers forming one pressured roller system taken along line 9-9 in Figure 1 and lZ&i~350 showing an embodiment includinq s~acer bearings and a differential speed roller arrangement which provide a spaced apart relationshlp therebetween; and Figure 10 is a diagrammatic i.llustration of one embodiment of an apparatus and process of this invention showing the pressurized roller systems and the tobacco material processed to recl~imed sheet-like ~ material.
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DETA.ILED DESCRIPTI~N OF THE EM~ODT~E~IT~
-Figures ]. and 2 illustrate an apparatus for con-ducting the process of this invention. The a~paratus comprises a first pressurized roller system and a second pressurized roller system~ As used herein, the term "pressurized roller system" means two rollers in roll contact and exhibiting a nip zone pressure sufficient to provide compression of tobacco ~aterial which passes therethrough into a more compressed form.
The apparatus inc.ludes ro].ler 10 which is a common ro].ler to each of the first and second pressurized roller systems~ The flrst ~ressurized roller s~stem includes substantially cylindrical roller l0 and another substantially cylindrical roller 2n in roll contact with one another. By the term "ro].l contact"
is meant that two rollers aligned with ro].l faces essentially paralle]. to each other have the rol.1 faces thereof in contact with one another for a distance along the length of each roller, and whereby each roller is capahle of being rotated about the longi-tudinal axis of each roller. Each of the rollers forming the first pressurized roller system are ~ounted such that the aforementioned rol.1 contact of roller ].n with roller 2n is substantially maintained during the -161:8 s~

process of the invention. Force is applied to each of roller lQ and roller 20 by compression rollers ll and 21, respectively in roll contact with each of ro]lers 10 and 20~ The force is provided in a direction shown schematically by arrow 12 and arrow 22, respectively.
The force can be provided to rollers 11 and 21 by jack screws 13 and 23, respectively~ Alternative force providin~ means can include hydraulic cylinders, or the l;ke~ Alternatively, the force providing means can be iO compression springs, tension springs, or the like.
Preferably, two compression rollers are positioned on each roller of the pressurized roller system and are positioned towards the end of the roller with which the compression rollers are in ro]] contact (as shown in Figure 2). ~ypica]]y, each of the two such compression rollers have diameters and a combined longitudinal length less than that of the roJler with which the compression rollers are in roll contact. The jack screw is positioned on each co~pression roller. Each of rollers 10 and 20 are ro-tated in the direction indicated by the arrows within the rollers. The rol]ers are rotated in opposite directions relative to one another in order that the tobacco ~aterial can be passed throu~h the nip of the rollers. Each of the rollers can be driven using a power source 26 (shown in Figure 2) such as a variable speed motor te~q. an electric ~otor having from about 1 to about 5 horse-power) which turns the rollers by a series of drive gears (not shown). The rollers are supported by support means such as a frame (not shown) to a chassis (not shown).
The second pressurized roller system includes roller 10 and another substantially cyl;ndrical roller ~0 in roll contact with one another. Each of the T~ 9 1,'4'~3~

rollers for~ing the second pressurized roller system are mounted such that the aforementioned roll contact of rol]er 1~ with roller 30 is subst,ant,ially maintained dur;,ng the process of this invention. Force is ap~],ied to each of roller 10 and 30 by compression rollers ]1 and 31 in roll contact with each of rollers ~0 and ~n, respectively~ The force is provided in a direct;on shown schematically by arrow ]2 and arrow 32, respectively. The force can be provided to rollers 11 and 31 by jack screws 13 and 33, respectively. Com-pression roller 31 and force providina means 3,~ are positioned as are the compression rollers and force providing means described hereinbefore. Each of rollers 10 and 3n are rotated in the direction indicated by the arrows within the rollers. ~he rollers are rotat,ed in opposite directions relative to one another in order that the tobacco material can he passed throuah the nip of the rollers. Each of the rollers can be driven using a power source 26 (shown in Fiqure 2) which turns the rol)ers by a series of drive gears (not shown). The rollers are supported by support means such as a frame (not shown) to a chassis (not shown).
Rol]ers positioned relative to one another in the configuration shown in Figure 1 form angle A which can be defined as that angle formed by the roll axis (i.e., the longitudinally extending axis3 of each of rollers 20, 10 and 30, respectively. The value of angle ~ can depend upon a variety of factors including the diameters of the various rollers. Typically, angle ~
ranges from less than 180 to a limiting angle defined by the diameter of the rollers, and preferably ranges from about 90 to about 1~0~

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In the preferred embodiment shown in F;qures 1 and

2, roller 3n has a. substantially smooth (i.e., non-grooved) roller face; and ro.ller 20 cont,ains the series of grooves therein. The series extends ,longitudinally along the roller wherein each groove extends ahout t,he periphery of the ro].],er. Roller 10 (whi,ch is in roll contact with both of rollers 20 and 30) comprises ei.ther a groove extending along the longitudinal axis of the roller and around the periphery of the roller in the region where the sheet-1ike material ulti,mate~y is provided, or a means such as spacer be~rings (shown in Figure 9) positioned at the ends of roller 10 in order to provide the re~uired spaced apart re~.ati.onship between the roller faces in the region where the sheet-like material ultimately is provi,ded~
~ 7hen compression rollers are employed at each endof the roller system ro.llers in order to provide the required nip zone pressures to the roll.er systems, it is most preferable that the grooved rollers have grooves posi.tioned along the ].ongitudinal length of the roller only in the region between the compression rollers (i.e., the roll ends are not grooved).
The forces between the rollers which t.ypically are required in the process of this invention can vary, but are those forces which are great enough to generate suffici.ent roller nip zone pressures in order to provide ultimately reclaimed (i.e., reconstituted) tobacco materials in a sheet-like form. That is, ! sufficient nip zone pressures are those sufficient to provide shearing, mixing, and formina of said tobacco material, and can be as qreat as is desired.
Typically, forces between rollers of at least about

3,000, and as great as about ln,OOn, preferably about

4,000 to ahout 6,000 pounds per ],lnear inch, are great T-161:ll enough to aenerate sufficient rol~er nip ~one pressures. Typically, the rollers are constructed of a metal materia1 such as hardened carbon steel or hardened alloy steel, or other material sufficient to withstand the compression.
The sizes of the various rollers can vary.
Typically, roller diameters range from about ~ inches to about ~ i.nches, preferably about 6 inches to about 8 inches; while roller lengths range fro~ about 4 inches to about 12 i.nches~ Rollers forming the two roller systems can each have diameters which are eaual, or the diameters of the various rollers can differ.
Rotational roller speeds ranqe, for example, from about a rpm to about ~0 rpm.
In the process of this invention, tobacco ~teria]
~0 (shown in Figure 1) which preferably has been physically premixed usi.ng conventi.onal means, is fed by hop~er 42 (which is shown as partially cut away in Figure 2) to feed zone a4 which feeds the tobacco materia]. to t.he nip of rollers ln and 20. The tobacco materia]. can vary and typically includes tobacco ~ust, tobacco fines, scrap tobacco which i.s recove.red from various processing stages and cigarette manufacture stages, scraps and/or sheets of wet for~ed recon-stituted ~.obacco (for example in dry form), scraps and/or sheets of dry formed reconstituted tobacco, tobacco leaf stems, and tobacco stems and stalks, and - the like. Various types of tobaccos and blends thereof can be employed.
The structural strength providing amount of tobacco leaf stem material included in the tobacco material can vary, and depends upon a variety of factors including the amount and size of that leaf stem materia]. which has a length and/or diameter areater (3~5~
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than the widt,h and d~pth of the roller grooves of the first roller system. For example, the a~ount, of leaf stem material is not so high as to provide an unde-sirable character such as undesirable taste characteristlcs t,o the resulti.ng rec].aimed material.
However, the amount of leaf stem mat.erial is at least that a~ount which is of a size that is capab].e of providing a desirab],e structura], strengkh to the reclaimed tobacco material forMed accordin~ to this inventj.on. For most practical purposes, the a~ount of leaf stem material reauired is at 1.east about 15 percent, preferably at 1ea.st about 18 percent, based c,n the total weight of tohacco materia]. which i.s employed.
Typically, the amount of leaf st.em material does not exceed about 60 percent, based on the total weiqht of tobacco material which i.s employed. The tobacco leaf stem material can be empl.oyed as is without further grinding, mi.llin~, pulping, treating with large amount of water, etc. The character of the toba~co leaf stem ~aterial is such that said stem material can provide a structural strength to the resultj,ng reclaimed tobacco material.. For exa~ple, the stem material can provide a fibrous character to the resulti.ng reclaimed tobacco ~aterial. It ;,s believed that the average size of the toba.cco leaf stem mater.ial. is an important factor in providing a rec1ai.med tobacco material of desirable structural strength. The average size of the t,obacco . lea.f stem material can vary, but the length and/or diameter thereof is larger than the qreatest width and depth of the grooves which extend about the periphery of the face of the first pressurized roller system.
Typi.cally, the average size of the tobacco leaf stem material which i.s employed in the process of this invention ranges from about 0~03 inch to about 0.~ inch T~161:13 35~' ;4 i,n diameter, preferably from about 0.04 inch to afbout O.l3 inch in diameter. Typical tobacco leaf stem material which is employed ranges in length from about 0.25 inch to about 4 inches, preferably from about 0.~75 inch to about 2 inches.
The moisture content of the tobacco material which is emp].oyed can vary~ Typically, a low ar.fount of moisture content requires a relatively greater a~fount of force between rollers in order to provide re~cl,ai~f.ed tobacco materials; while a high moisture content ref~uires the undesirable and energfy intensive dryinf~f processes attendant in conventiona] water hased reconstitutf.~d tobacco processes. Typi.cally, the~
tobacco m~.fterial ~hich is employed in the process of this i.nvention exhihi.ts a moisture content of at least about l4 weigfht percent, preferably at least about 15 weight percent; while the upper l;,mit of the moisture content is less than about ~0 weight percent, and typical]y is as gfreat as about 25 ~eight percent, ~referahly as rifreat as about .l~ weight percent, based on the dry weight of the tobacco materialf. and moisture.
It is believed that moisture imparts a softening of tobacco material as well as provi.ding a material having a pliability sufficient~l.y low to allow for the utiliza-tion of a desirable force duri.ng the mixincff process.It is desirable that the moisture content not be overly hi.gh as to CaUSff? an undesirable pliability of fiber material. thereby preventingf adeauate intermixinfgf of fibers and resulting in a product havingf relatively poor tensile strength.
The mixed and pre-formed tobacco material 46 (shown in Figure 1) which passes througjfh and leaves the first pressurized rol.ler system is fed into zone 48 - whi.ch is a regfion capable of feeding the tobacco T~161-;14 :~2~35~

materia] to t,he second rol].er system. The tobacco material exitinq the first ro~.ler syste~ can have a tendency to stick to the rollers, and the materia1 can be removed from the rollers (particularly roller 2n as shown in Figure 1) by scrape 50. Scrape 50 can be a series of needles, a comb-1i.ke configuration or a knife-like means such as a doctor blade posi,ti.oned against the ],ength of the face of the roller so as to remove (i.e., scrape) the tobacco material from the face of the roller. Most preferably, scrape 5n is posi.tioned non-tangent;.ally to the surface of the roller. For example, scrape 50 is posit,ioned a~ainst the face of roller 20 at a circumferentia]. location on the surface of the roller within an arc of about 10 to about ~5 re~ative to t.he point at which rollers ].0 and 20 meet in roll contact. Preferahly, the scrape is positioned substantia],ly para],lel (i.e., wi.thin an angle of about 15) relative to the tangent of the rollers for~ed by the point of the ro11 contact of rollers 10 and 2n. ~crape ~n is attached to the ch,assi.s or frame of the apparatus (not shown) in order to mai.ntain the posi.ti.oning thereof a~ainst the face of the roller.
If desired, zone 4~ can be employed as an auxiliary feed zone where tobacco material, particu-. larly small particle size material such as tobacco dust and/or tobacco fines, can be added to the mixed and pre-formed tobacco materia], 46 exiting the first roller syste~ into zone 48. In particular, the compressed, admixed tobacco material provided by passing the tobacco material through the first pressurized roller system is contacted with tobacco dust and/or tobacco fines, or other such material, in zone 48. ~one 48 can include a slide 52 which is a hopper or other means for directing tobacco material 46 in the second pressuri.zed

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ro,ller system. The tobacco material 46 in zone 4P, which has been mixed and pre-formed under presfiure in the first pressurized roller system is aenerally a macerated, ~round or pressed tobacco material having some reconstituted tobacco character.
Tobacco material 4fi is further formed under pressure into the desired sheet-like material by passing tobacco materia]. 46 through a subsequent second pressurized roller system. In the preferred embo~iment, shown in Fi.gures 1 and ~, tobacco materi.al. 46 is passed through the nip of rollers In and 30.
The sheet-like tobacco materi.~l 5~ exits the second roller system and can be removed from the surface of rol].er 10 usin~ scrape 56. ~crape 56 is attached to the chassis or frame of the apparatus tnot shown) in order to mai.ntain the posi.tioninq thereof against the face of roller 10.
Reconstituted tobacco material i.n sheet-like form can be provided throu~h the assi.stance of scrape 56 having the form of a doctor blade or other such means positioned against the face of the rol.ler ]0 and extending along the face of the roller. ScraPe 56 is positioned along that portion of the length of the ro].ler wherein tobacco material tends t,o stick to the roller. Scrape 56 is most preferably positioned non-tangentia].ly to the roller. For example, for the preferred embodiment illustrated in Figure 1, scrape 56 is positioned against the face of rol].er ln at a circumferential locati.on on the surface o the roller within the arc of about 10 to about 30~ relati.ve to the point at which rollers 10 and 30 meet in roll contact and thereby are positioned in a spaced apart relationship. Preferably, the scrape is positioned T-161:16 ~Z~ }3~

substantial].y para].]el (i.e., within an angle of ahout ]5) relative to the tangent of the rollers formed by the ro].]. contact of rol.lers 10 and 30. Scrape 57 (shown in Figure ].) provides a means for removing tobacco material from the surface of smooth roller 30 Scrape ~7 is a doctor blade or other such means positioned against the face of the rol].er. ~crape 57 is positioned against the face of roller 30 in much the same manner as scra~e 56 is positioned aaainst roller 10~ The tobacco materi.al 54 can be directed from the apparatus by collection bin 5~ or other removaJ. means, and then col].ected.
Figure 3 i.l].ustrates a series of grooves 7n positioned along a rol].er, and each groove has a top portion 72 (i.e., to~ards the surface of the roller face) and a bottom portion 74 (i.e., toward the inner portion of the ro].ler). The series of grooves extends longitudinally along rol].er 20 or a portion thereof.
The grooves 7~ can be incorporated into ro].ler 20 of the first press~lrized ro].ler system by techniaues such as machinin~ using a suitahle ].athe. Each groove completely circumscribes ro].ler 2n. Preferably each groove has a shape substanti.ally si~i.lar to the other arooves which extend alona the roller. The grooves can extend about the roller in a radial fashion, a helical fashion, or the like. Preferably, the arooves each circumscribe the roller substantially transversely re.lative to the lonqitudinal axis of the roller. Top portion 72 can be, for example, pointed, or flattened (as illustrated in Figure 3). ~hen flattened, top portion 72 typically ranges in width from about n.nlO
inch to about 0.015 inch. Generally, the f].at.tened top portion 72 is narrow enough so as to not reauire excessive force in order to maintain roller contact i.n ~Z~;~3S~

the pre.ssurj.zed rol].er system; whi,].e flattened to~
portion 72 is wide enough as to not deform to a substantial extent under typi.cal. nip zone pressures.
Rottom portion 74 can be pointed, rounded, or flatt,ened (as il].ustrated i.n Figure 3). ~hen flattened, bottom portion 7~ typically ranges i.n width from about O.nO3 inch to about ~.007 inch. Generally, hottom portion 74 is narrow enough so as to provide suffici,ent mixing action of the tobacco material. The mixing action i.s helieved to be provided by the compression feeding performed by the re].a.tively large size ]eaf ste~s which carry the tobacco particles into the grooves.
Flattened bottom portion 74 is wide enough so as to permit the release of tobacco material from the surface region of the rol.ler after processing. Tn particu].ar, a botto~ portion 74 which is overly narrow or pointed can tend to trap tobacco materi.al j.n the groove and prevent release of the tobacco material therefrom. The depth d of the groove can vary and typically ranges from about 0.015 .inch to about nAn~5 inch. The depth is defined as the radi.al distance between thP bottom portion of the groove and the top portion of the groove. The areatest width w of the groove can vary and typical.ly ran~es from about n.015 inch to about o~o~o inch. The width is defined as the ].atera].
distance measured across the groove. The ~ltch p of the groove can vary and depends upon a variety of factors inc].uding the type of tobacco material which is processed, the moisture content of said tobacco material, the l.eaf stem content of the tobacco materia.l, the shape of the groove, and the like. The pitch is defined as that lateral distance from the the cent.er of top portion 72 to the center of the nearest adjacent top portion 72. Typically~ a pitch of about T l~

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0.02 inch (i.e., about 1/50 inch) to about 0.06 i,nck (i.e., about 1/]6 inch); prefer~bl.y about 0.03 inch (i.e., about 1/32 lnch) is usefu]. for most applica-tions. The shape of groove 70 can vary and depends upon a variety of factors. ~owever, each qroove has a maximum width near the surface of the roller and a mlnimum width near the bottom of the groove. ~ach groove has sloped sides (i.e., non ~erpendicular to the roller face) and preferably each. groove i.s aeneral],y "V" shaped. For exanple, pressurized roller system having a roller co~prisinq a series of grooves each having a slopinq inner edge each groove circumscrihina an angle A' of less than about ].20, can mix tobacco material suitably well; and a pressurized roller syste~
havi.ng a roller comprising a series of grooves each having a slopinq inner edge, each groove circumscrihin~
an ang].e A' of areater than about hO, can release processed tobacco materia]. suitahly wel].~ The preferred angle A' ranges from about 6n to about 12n, and is most preferably about 9~.
Figure ~ illustrates two rol~.ers of the second pressurized roller system (desi.gnated as rol.lers ]O and 30, respectively) in rol.l contact with one another towards end region 71 and other end region 72 of each roller. ~oller 3n has a substantially s~ooth surface, The roller faces of each roller are positi.oned in a spaced apart relationship in region 73 which extends along a portion of the longitudinal length of rollers 10 and 30. The spaced apart relationship and the corresponding region 73 is provided by groove 7~ which extends longitudinally a].ong a portion of roller ln.
The groove can be incorporated into the roller hy techniques such as machining us;.ng a suitable ].athe.
The groove complet.ely circu~scribes the roller in the T-161~19 ~6~5~

reg;on which the groove extends longitu~ina].ly along a portion of the roller. The distance which roll.er ln and ro~ler 30 are positioned in a spaced apart relati.onship can vary and is generally a distance which is capable of provid;.ng the sheet-].ike materia~ of an acceptable thickness~ Generally, the distance which roller lO and ro].ler 30 are positioned in a spaced apart relationship (i.e., the radi.al distance between the roller face of roller ~0 and the roller fac~ of roller ~0 as ~easured in region 78) ranging from about 0.003 inch to about 0~02 inch, with about O.nO6 i.nch preferred.
Figures 5, 6, 7 and P, each illustrate other profiles for roller ln, which roller is capable of being in rol]. contact with another roller ~not shown~
at the previously deccrihed regions 71 and 72 toward each end of roller lO. Ro].ler ln comprises groove 75 which extends longitudinally therealong and co~p~etely circu~scrihes the roller in the reaion which the groove extends longitudinally along the portion of the roller.
Typically, a groove 75 can extend from about ]0 to about 90 percent of the lon~itudina]. ~ength of roller.
Each of Fiqures 5, 6, 7 and 8 illustrate various aspects by which groove 75 of roller 10 can be formed.
In Figure 5, a series of grooves 80 are positioned along roller lO within groove 75. Each groove 80 has a top portion 81 (i.e., towards the surface of the roller face) and a bottom portion 82 ti.e., toward the inner portion of the roller) within groove 75. The qrooves can be incorporated into the ro].ler by techniaues such as machining using a suitable lathe. Each qroove 80 completely circumscribes the ro]ler. Preferably each groove 80 has a shape substant;.ally sim;lar to the other such grooves which extend along the rol.ler. The T-~61:2n grooves can extend about the ro1.~.er in a radia1, fashion, a helica], fashion, or the like. Preferahly, - the grooves circumscribe the rol,ler substantia11y transversely relative to the longitudinal axi.s of the roller. ~op port,lon 8l can be, for example, pointed, or fl.attened (as i].lustrated in Figure 5). ~Jhen flattened, t.op portion 81 typically ranqes in width from about O.nO8 inch to about 0.0l5 ;.nch. Rottom portion R2 can be pointed, rounded, or flattened (as illustrated in Figure 5). ~Jhen flattened, bottom.
portion 82 t.ypically ranges i.n width from about o.no3 i.nch to about 0.007 inch. General].y, bottom portion 82 is narrow enough so as to provide further mixing action of the tobacco material. The mix;.na action is bel,ieved to be provided by the compression feeding performed by the relatively large size leaf stems which carry the tobacco particles into the grooves. F~.attened bottom portion 82 is wide enough so as to permit the release of tobacco mat.erial from the surface region of the roller after processing~ In particu1.ar, a bottom portion 82 which is overly narrow or pointed can tend to trap tobacco material in t.he groove and ~revent release of the tobacco material therefrom. ~he depth d' of each groove 80 can vary and typically ranges from about O.OlQ inch to a,bout 0.08n inch. The depth is defined as the radial distance between bottom portion 82 of groove 80 and the top portion 8l of groove 80.
The greatest width w' of groove 80 can vary and typically ranqes from about O.nl5 inch to about 0.040 inch. The width is defi.ned as the lateral distance measured across the groove. The pitch p' of the ~roove can vary and depends upon a variety of factors including the type of tobacco material which i.s processed, the moisture content of said tobacco T-l6l-21 35~

material, the leaf stem content of the tohacco material, the shape of the groove, and the l.ike. The pitch is defined as that lateral d;.st*nce from the the center of top portion 81 to the center of the nearest adjacent top port,;on 81. ~yplcal1y, a pitch of about 0.02 i.nch (i.e., about 1/50 inch) to about n.06 inch (i.e~, about 1/16 inch); preferably about 0.03 inch (i~e., about l/32 inch) is usefu1 for most applica-tions. The shape of groove sn can vary and depends upon a vari.ety of factors. Ho~ever, each groove has a maximu~ width near the surface of groove 80 and a minimum width near the bottom of groove 80~ ~ach groove has sloped sides (i.e~, non perpendicu]ar to the roll.er face) and ~referably each groove is generally "V" shaped~ For example, pressurized rol].er system having a ro],ler comprising a series of grooves each having a slopina lnner edge each groove circu~scribi.ng an angle A" of greater than about 6n, can mix tobacco materia.l suitably wel.l; and a pressurized roller system having a ro].].er comprising a series of qrooves each having a sJ.oping inner edge, each groove circumscribing an angle ~" of qreater than ahout 6n~, can release processed tobacco material suitably we].l. The preferred angle ~" ranges from abollt hOC to about 12n~, and i.s m~st ~referably ahout 90~. The depressed depth d" of groove 75 is that radial distance ~easured from the outermost surface of the ro].]er face at reqion 71 to the top portion 81 of groove 80. In particular, the outermost surface of top portion 81 of each groove 8n does not extend as fa.r out~ard from the center of roll.er 10 (as measured from the longitudinal axis of the roller) as does the outermost surface of the roller face at region 7]. Typically, de~ressed depth d" of groove 75 varies for a particular tobacco material T-16].~22 335~

2~

depending upon factors such as the moisture content, of the tobacco material, the composit;.on of the tobacco material, etc. Generally, depressed depth d" ranges from about. o.on8 inch to about O.nl2 inch, with about 0.006 inch being preferred.
In Figure 6, roller lO has groove 75 extending longitudinally therea]ong. Groove 75 has a substan-tially smooth surface 85. The depressed depth ~" of groove 75 is that radial distance measured from the outermost surface of the roller face at region 71 to surface 85 of the qroove. Typically, the depressed depth of the groove is that dept.h which provides a rec]aimed sheet-like tobacco mat,erial. Factors such as the tobacco materi.al composition, moisture content of the co~position, t.he presence or absen.ce of binders, forces between rollers, etc., will dictate the depressed depth of t.he groove. Typically, the depressed depth d"' for the embodiment shown in Fi~ure

6 ranges from about O.nOA inch to about n~0l2 inch.
In Figure 7, roller 10 has groove 75 extending longitudi.nally therea,long. Groove 75 has a further recessed or uneven surface 88 which can exhiblt a variety of cross sectional shapes such as sinuso;dal, V-shaped, Il-shaped, etc. The average depressed depth of groove 75 of t,his e~bodiment can vary and depends upon factors such as those disclosed hereinbefore the other such e~bodiments and is the radial distance measured from the outermost surface of the roller face at region 71 to surface P,8 of the groove. The particular shape of surface 88 generally is selected in order to provide the desired surface properties to the sheet~like material. which i.s provi.ded.

T- 1 6 1 2 ~

35~

2~, In Figure P!, rollers ~0 and 30 each are pos;tioned in a spaced apart relationship in region 7~ ~7hich extends a].onq a portion of each ro.ller. ~ach of rollers lO and 30 are in roll contact ;n region 71, and surace ~9 of roller 30 and surface 90 of roller ].0 each for~ a somewhat sinusoidal shape longitudina~.ly along end roller. The spaced apart relationshi.p between the rollers, or the depressed depth of the so~ewhat sinusoidal shaped groove can vary, and general].y ranges from about n.no4 inch to about n.nl2 inch, wi.th about 0.006 inch being preferred. The resulting sheet-like material having a wavy or corrugated-type profile can be employed in providing cut filler having an improved filling capacity.
In F;gure 9 ro]ler face 9l of roller 3n and ro,ller face 92,roller lO are positioned in a spaced a~art relat.].onship in re~ion 93 al,ong the longitudinal axi.s of each roller. The spaced apart re]ationsh;.~ of the roJ,lers is provided by idl.er bearings 95 whi.ch encircle each end of roll.er lO and spacer ring qfi which encircles and is mounted to each id].er bearinq, or other such ~eans. Machining of each end of the ro]ler can be performed as reauired in order to provide the desired flt of idler hearing assembly and spacer rin,a~
Roll contact is provided between the roll face of roller 30 and either a surface of the idler bearinq assembly or the spacer rin~ encirclina ro],ler lO. The surface of the idler bearing assembly and encirclin~
spacer ring extend longitudinally along a portion of that roller. Roller face 92 of roller lO can be grooved, roughed, or smooth (as shown in Figure ~).
The spaced apart relationship of the rol].ers i.s a distance which approximates the t,hickness of sheet-].ike reclaimed tobacco material, and generally the distance T-].6]:24 ~26U~5~

ranges from about o.on3 inch to about 0.007 inch, with about 0.004 inch being preferred. Of particular interest is the fact that for this emhodiment the drive gears (not shown) which turn ro].lers 10 and ~0 can be arranged in order that there is a linear speed differentia]. between the roller surfaces of each of rollers 10 and 30~ The linear speed differential between rotating rol].ers 10 and ~0 will depend upon factors such as the character of the tobacco material hei.ng processed, the roller diameters, etc. Typically, llnear speed di.fferentials ranqe from qreater than n i.nches per minute, preferably ~reater than about ~0 inches per minute, up to about 120 inches per mi.nute, preferably up to about 60 inches per minute, for a pair of 4 i.nch diameter ro]lers. It is belleved that an additi.onal sheari.ng action can be created hetween the rol].ers rot~ting at different llnear speeds that is capa~le of aliqning more of the lndividual tobacco fibers, thereby providing the capabil.ity of producin~ a homogeneous and strong sheet.
Figure 10 illustrates another apparatus for conducting the process of this i.nvention. The apparat.us comprises first pressurized rol.ler syste.m and another first pressurized rol].er system; and second pressurized roller system and another second pressurized rol].er system. The apparatus inc].udes roller 110 which is in roll contact with each of rol]er 112 (thus formin~ the first ro].ler system) and roller 114 (this formin~ the second pressurized rol3.er system). In addition, roller 120 is in roll contact with each of roller 122 (thus for~ina the other fi.rst roller system) and roller 124 (thus forminq the other second pressurized rol3.er system). The size, shape and composition of the rollers are simi.lar to that of those T-161-;..5 ~5 rollers descrihed for the embodiment described her~-inbefore. Each of rollers ll2 and 122 are in ro.ll contact with one another, and preferably each roller has a series of grooves in the longitud;.nally extendi.n~
5 roller face thereof. Each of ro].lers 112 and 122 are generally as described hy Figure 3. Each of rollers 114 and 124 are in ro].l contact with one anot.her; and preferably each roller has either a aroove extendin~
alon~ the longitudinal axis of the roller and around 10 the periphery of the roller ln the re~ion where the sheet-like material ultimately is provided, or a means such as spacer bearings positioned at the ends thereof in order to provide the necessary spaced apart relationship between substantially s~ooth roller faced 15 rollers llQ and 120, respectively. Poller 1].4 and 12~
are ~enerally as described in Figures 4, 5, h, 7, 8 and 9. Rollers ll2, ].10 and lla~ and rol.lers 122, 120 and 124 each for~ angle B and angle C, respectively, for~ed by the roll axis of each of the respective rolJ.ers.
20 Angles B ~nd C are less than 1.~0, and preferably range from about 90 to about 15n. Force is applied to each of ro].lers 110 and 120. For example, rol]ers lln and ].20 can be in rol] contact with compression rollers 13n and ].32, respecti.vely. Each of compression roll.ers ]30 and 132 ~re equipped with jack screws 134 and ~36, respectively~ The force is applied to each of rollers ].10 and 120 indicated by arrows 1~ and 139, respectively. Each of rollers 112, 114, ]22 and 12~
are mounted on horizontally extendina restrai.nts 140, 141, 142 and 143, respectively. The restraints (which are shown as partially cut away) al].ow the respective ro].].ers to be mounted such that each of rollers 112 and 122, and rollers 114 and 124 can be in roll contact with one another. The restraints a]low the respect;ve T-161:26 ~ZÇi(~350 rollers to he maintained in roll cont,act under the conditions necessary to provide the respective pressuri.zed rol].er systems. ~he restraints can be metal tracks upon which the rollers are mounted, *nd can be supported by a frame or chassis (not shown).
Forces between rollers are similar to those forces for the embodiment described here;.nbefore. Rollers 112 and 122 of the first pressurized ro].ler systems each have scrapes 150 and ].52, respectively positioned t.hereagainst~ Scrapes 150 and 152 and the positioning thereof are simil.ar to the corresponding scrape described for the previously described embodiment.
Ro].lers 114 and l2~ of the second pressuri,zed roller systems each have scrapes 15~ and 156, respectively positioned thereagainst. Scrapes ].54 and 156 and the positioning thereof are similar to the corresponding scrape descri.bed for the previously described embodiment. ~ollers 110 and 120 can have scrapes 157 and 158, r~spect,ively, positioned against the rol].
faces thereof. Scrapes 157 and 15~. can be doctor blades or other such means for cleani.ng the surface o~
the ro3.].ers of tobacco material~
In the process of using the a~para~lJs descri.bed in Figure 10, tohacco material 16n ~nd 162 is contained ln hoppers 164 and ]66, respectively~ ~obacco mater~a].
160 passes through the nip zone of rollers 110 and 1l2 which are rotated in opposi.te directions such that the tobacco material passes therethrouqh. The compressed, admixed tobacco material 16~ then passes throuqh the nip of rollers 110 and 11~ which are rot~ting in opposite directions. Sheet-like material 17n is formed thereby. Similarly, tobacco material 152 passes through the nip æone of rollers 120 and 122 which are rotating in opposite directions. The compressed, admixed tohacco material 159 then passes through the T-161:27 3~

2~

nip of rollers ]2n and 124 wh,ich are rotatina i,n opposite directions. ~heet-like maker;.al ~74 is for~ed thereby. Each of sheet-like materi,als 17~ and 174 are passed through the nip of a latter pressurized roller system including rollers 180 and 182 which are in ro.ll contact with one another. Roller 1~0 has a. substan-tially smooth surface and roller ~2 has a recessed groove or other such means such that a reaion of spaced apart relationship is provided between the rol.ler faces. The spaced apart relationship ranges from about 0.008 inch to about 0.03 inch. The rol.l.ers are rot,a~ed in opposite directions such that the reclaimed tobacco material passes throu~h the ni.p t.hereof. Hi~h nip zone pressures (i.e~, in excess of about 3,noo pounds per linear inch) are ma;ntained between rollers ].8~ and 182 force providing means such as compression rollers ],85 and 1~6, res~ecti.vely which are in rol], cont.act therewith and are equipped with jack screws 1~7 and lR~, respectively. Sheet-like reclai.med tohacco material l9B is provided as product. Each of the rol.lers of the pressurized roller systems can be driven by a power source (not shown) by a series of drive ~ears (not shown). The rollers are supported by support means such as a fra~e (not shown) to a chassis (not shown).
The process of this invention employs first and second roller systems described previously. It .is believed t.hat the shearing action provided by each pressurized ro].ler system provides a breakdown of individual parti.cles and fibers of tobacco ~aterial.
Such a breakdown of particles and fibers is believed to provide a separati.on of some of the natural binding materials from the particl.es and fi.bers, which natural binding materials can provide a bindin~ actlon to the T- 1 6 1 : 2 ~

., .

3S~

~9 tobacco materi~l ln order to provide a resultinq strand material,. In addition, it is beli.eved that shearin~
and mi.xi,n~ act;.on provide~ by t,he pressuriz,ed roller syste~. can provide a sufficient mechanical interlockinq 5 of fibers and partlcles, thus for~ing a type of matr;x.
Thus, a first pressurized roller system containing ~
roller havina a series of qrooves havin~ a size sma].].er than that of the tobacco leaf stem material is believed to provide a separation of leaf stem material, m;.xing and remi.xing of tobacco material, coalescin~ and agglomeration of tobacco material, and bindinq of tobacco materi.al with natural binding materials of tobacco material.
The rec]aimed t.obacco which is provided accorAing 15 to the process of this invention can be provide~
generally in the form of a sheet. The sheet-like mater;.al exhi.bits ~ood flexibil.ity and tensil.e strength. Typically, the tobacco material in the form of a sheet, exhibit,s a structura]. st,rength which approaches that of tobacco leaf. By the term "sheet"
as used here;.n is meant that the tohacco material is in a form wherein the length and width thereof are substantiall~ qreater than the thickness thereof.
Typically, the thickness of the sheet approxi~ates that of tobacco leaf, cured or ~rocessed tobacco 1eaf, or wet reconstituted tobacco sheet product~ For examp]e, the thi,ckness of the sheet can ran~e from about n.oos inch to about n.o40 inch, preferably from about O.Ol~
inch to about 0.020 inch. The len~th and ~idth of the sheet or strip of reconstituted tobacco material can vary. The wi.dth of the sheet genera.lly is determined hy factors such as the longitudinal distance which the rollers of the second pressurized ro].ler system are in a spaced apart relati.onship, the len~th of the ~eans T-161:29 ~L26(~350 ~o for rernovinq the reclaimed tobacco material fro~ th-~ro].ler face of the roller of the second rol],er syste~, and the like. The sheet-like material exhibi.ts aood flexibility and tensile strength. The sheet can be cut as are tobacco leaf or wet formed reconstituted tobacco material (e.g., in str;.ps of about 32 cuts per inch~
and employed as cut filler in the manufact,ure of cigarettesO
The fol.lowing examples are provided in order to further i,llustrate various em~odiments of the invention but should not be construed as limiting the scope thereof~ Unless otherwise noted, all parts and percentages are by weight.

EXAMPLE l An apparatus which is generally descr;.bed in Figures l and 5 is provided, except that rol].~rs 20 nd 30 each have a substantia~.~.y smooth surface. The ro]lers are subst,antial]y cylindrlcal, constructed of harclened car~on steel, and have a diameter of 4 inches and a rol].er face having a length of 4 irches. Poller 10 is generally described in Fiqure 5. Roller ln comprises groove 75 which extends 2 inches ].ongitu-din~lly along the roller, and the 1 inch dist,ance along the roller face at each end of the ro~ler is relatively smooth~ The face of the rol.ler within groove 75 comprises a series of grooves extending in a radial fashion about the periphery of the roller within groove 75. The depressed depth d" of groove 75 is O.nlO inch, and the depth d' of each groove sn is o.oo9 inch~ The pitch p' of each qroove ~0 is n ~03] 25 inch, and the angle A' is about 90~. The top portion Sl of each groove 80 is o.on3 inch, and the botto~ portion ~2 of T-161-3(, ~2~(~3SO
~1 eah c~roove 80 i.s f1attened by a distance of n.on3 lnch. Rollers 20, 1~ and 30 are operated usinq a variable speed dri,ve using a variah~e s~eed dri7e usincJ
a variable speed 1 horsepower electric motor at a speed of 16 r~m, and nip zone pressures between each of rollers 10 and 30, and rollers ln and 2n of 3000 pounds ~er linear inch are generated. The angle A provided by - the centra], axis of roller 20, ro].ler 10 and roller ~0, respectively, is 15n. Scrape 56 in the fo~ of a comb is positioned so AS to remove the reclaimed tobacco material from rol.ler ln~ Force is provided to each of rollers 1~, 20 and 30 by two compression rollers positioned in ro]l contact with each of rol].ers 1~, 2~, and 30~ Each compression roller is positioned at one end of each of rollers 10, 2n and ~n. The compression rollers are about 1 inch in ].ongitudina' length and about 2 inches in diameter. Force is pro7ided t,o the compression rollers by jack screws~
A blencl of scrap t.obacco i.s provided~ The blend is about as percent cut tobacco filler fines havinc~ an avera~e parti,c.le diameter of less than 2n Tyler mesh, about 17 percent tobacco dust from a r1olins ~IK9 r1aker~
and about ~8 percent ~7i.nnower throw stems from a ~lolins ~1K9 ~laker. The blend exhibits a moisture content of about 10 p~rcent. A resultant blend is provicled by contactincJ the blend with enough water to provide a b].end exhibitincl a 17 percen`t ~oisture level. The resultant blend is introduced into the apparatus and a reclai~ed tobacco material in the form of sheet-l.lke tobacco material havinc~ dimensions of inches wide and 0.04 inch thick is provided. The resultinq sheet-l.ike ~aterial i.s si~i1.ar in character to wet reconstituted T~ ], ~;(3350 .~2 tobacco product, and exhibit,s a fl.exibility and tensile strength sufficienr. to allow for cutting thereof int,o strips of 32 cuts per inch without signifj.cant hreakage thereof~

EXAMPLE ~

To the blend of scrap tobacco described in Example 1 is added broken, dried pieces (ori.gina]ly about. 0.025 inch thick hy about 4 inches in length and width) of wet formed reconstituted tobacco ~ateria,l product. To the tobacco material mlxture is added water. The resultant blend comprises 15 percent of the wet for~ed reconstituted tobacco material. and a 25 percent moisture level . The resultant blend is processed using the apparatus described in Example ]., except that the depressed depth d" of aroove 75 is ~.nn7 inch rather than ~.r!l5 i.nch. The resulting sheet-like recon-stit,uted tobacco mat,erial. i.s strong and pliable.

-To the blend of scrap tobacco described in Example 1 is added enough guar gum, qlycerine and water to provide a resultant blend comprising In percent binder, 5 percent humect.ant and a ~0 percent, moisture ].evel.
The resultant blend is processed using an apparatus genera],ly described in ~xample 1. Rol.ler 3n has a substantially smooth surface. ~oller 10 has a series of grooves therei,n as shown in Figure ~. Roller 1~ has grooves extending about 2 inches along the rol].er face, and the 1 inch distance along the roller face of each end of the roller is relatively smooth~ A cross T-161:~2 . , lZ~350 section of ro.ller ]0 is generally described in Fiqure 3. Roller 1 n has a groove depth d of o nos inch, ~itch p of 0.03l25 inch, a flattened top portion 72 of o.n~
inch~ and a flattened bottom portion 74 of 0~0~ inch.
Rol].er 20 is eaui.pped at each end thereof w;,th an i.dler bearing assembly and spacer ring generally as described in Figure 9. Each idler bearing assembly and spacer ring extends about 1 inch along the longitudinal lengt,h of roller 2n. The idler bear;.ng assembly and circum-scribinq spacer ri,ng provides a spaced apart, relat-on-sh;p of n.oo3 i.nch between the ro],].er faces of rollers 10 and 20 in the 2 inch region a].ong the ~rooved roller face of roller 10. Roller 2n is rotated at a linear differential speed of from ~3.7 inches per minut.e to 118~8 inches per minute greater than that of the rolJer 10 surface during the process;.nq of the resultant bl.end~ The resulting pliable sheet.~li.ke tobacco material havinq dimensions of 2 inches wide and n.01 inch thick is provided by passing the tobacco material between the nip of rolJ.ers 10 and 2n. The sheet-like material is provided in region 4~ as the material is remo~7ed fro~ rolJ.er 10 by scrape 5~.

A blend of scrap tobacco was provided by con-tacting 114 grams ~innower throw stems fro~ a Molins r1K9 Maker, 50 grams tobacco dust from a rlolins MK9 ~1aker and 136 grams cut filler fi.nes having an averaqe partic3.e diameter of less than 20 Tyler mesh. The blend exhibits a moisture content of about 1~ percent.
The blend is contacted with enough water (about 5h grams) to provide a blend exhibitinq 25 percent T-161:3~

~6~5~

moisture leve] which is lowered to 20 percent moisture ].eve3 after the blenA is a]lowed to set overnight~ The resultant blend is designated as ~esultant ~lend A.
; A blend of scrap tobacco is provided by contacting 75 grams of broken scraps of dried wet reconst.jtuted tobacco (origina].ly about n.25 inch to about 4 inches in size), 50 grams of tobaco dust fro~ a Molins MK9 Maker and enough water (about 2~ grams) to provide a blend exhibiting about 25 percent moisture level which is lowered to about 20 percent moisture level. after the blend is all.owed to set overnight. The resultant blend is designated as Resultant Blend ~.
An apparatus generally descrihed in Figure l and Example 1 is provided. Rol].er 2n has a diameter of ~
i.nches and has grooves extendinq about 2 i.nches along the roller face, and the ] inch distance al.ong the roller face at each end of the ro].ler is relatively smooth. A cross section of ro].ler 20 is aenerally described in Figure 3. Roller 2n has a groove depth d of 0~009 inch, pitch p of n.n3]25 inch, a flattened top portion 72 of 0~008 ;nch and a flattened botto~ portion

7~ of 0.00~ inch. Rollers ].0 and 30 each have a diameter of 4 inches and have substantially smooth surfaces. Rol.ler lO is eguipped at each end thereof with an id].er bearing assembly and spacer ring generally as described in Figure 9. Each idler bearing assembly and spacer ri.ng extends about I inch along the longitudinal l.ength of roller lO. The idler bearing assembly and spacer ring provides a spaced apart re]ationship of 0.005 inch between the roller faces of rol~ers 10 and 3n, and rollers lO and 2n, in the 2 inch region along the ro].ler faces. Roller 10 is rotated at ~-l61 3~

35~

a rotational speed of 8 rp~. The speed of rotatin~
rol].er ]O relative t,o roller 2n is 16/9; and the speed of rotating rol.ler ].0 re],ative to roll,er ~,0 is 4/8.
Resultant Blend A is fed into the apparatus at feed zone 4~ by way of hopper 42. Resul-tant- ~]end R is fed i.nto the apparatus a feed zone 48. The resu~tinq sheet-like tobacco materia.l ~4 which exhibits the second pressurized roller system is pliable, is simi],ar in character to wet reconstituted tobacco product, and exhibits good tear strength~

The .sheet-like tobacco material provided in Example 4 is further processed using the apparatus described in Example 4~ In particular, the sheet-].ike product is fed randorly through the apparatus a second time by way of hopper ~2. The resultinq sheet-like tobacco material which is provided by the futher processing exhi.b;,ts good tear stren~th and p],i.ability~

T-16].-85

Claims (42)

What is claimed is:

1. A process for providing reclaimed tobacco material in sheet-like form, said process comprising the steps in combination (a) providing tobacco material including tobacco leaf stem material, the tobacco material having a moisture content less than about 30 weight percent, and then (b) passing the tobacco material through the nip of a first pressurized roller system having two rollers exhibiting a nip zone pressure sufficient to provide compression of said tobacco material thereby providing compressed, admixed tobacco material, wherein at least one of the roller faces comprises a series of grooves, which series extends longitudinally along the roller and each groove extends about the periphery of the roller, wherein each groove has a maximum width near the surface of the roller and a minimum width near the bottom of the groove, wherein each of the grooves has a maximum width and depth which is smaller than the length and/or diameter of tobacco leaf stem material, and wherein the tobacco leaf stem material is employed in a structural strength providing amount, and then (c) forming under pressure reclaimed tobacco material in sheet-like form by passing the compressed, admixed tobacco material through the nip of a second pressurized roller system having two rollers exhibiting a nip zone pressure sufficient to provide the reclaimed tobacco material, wherein the roller faces of the rollers are positioned in a spaced apart relation-ship in the region along the rollers where the reclaimed tobacco material is formed, and wherein T-161:36 the spaced apart, relationship between the faces of the rollers provides a sufficient distance there-between to provide formed sheet-like reclaimed tobacco material.

2. The process of Claim 1 wherein said of tobacco material is provided in the absence of a binder.

3. The process of Claim 1 wherein the amount of said tobacco leaf stem material in said tobacco material is at least about 15 percent, based on the total weight of said tobacco material.

4. The process of Claim 1 wherein said nip zone pressure is at least about 3,000 pounds per linear inch.

5. The process of Claim 1 wherein said tobacco material which is provided in step (a) includes scraps and/or sheets of wet formed reconstituted tobacco.

6. The process of Claim 1 wherein the tobacco material exhibits a moisture content between about 15 weight percent and about 18 weight percent.

7. The process of Claim 1 wherein the tobacco material exhibits a moisture content between about 14 weight percent and about 25 weight percent.

8. The process of Claim 1 wherein the amount of said structural, strength providing amount of leaf stem material, ranges from about 15 to about 18 percent based on the total weight of tobacco material which is employed.

9. The process of Claim 8 wherein said structural strength providing amount of tobacco leaf stem material ranges from about 0.03 inch to about 0.2 inch in diameter, and from about 0.25 inch to about 4 inches in length.

T-161:37

10. The process of Claim 1 wherein said tobacco leaf stem material is not pre-ground.

Il. The process of Claim 1 wherein each of said grooves is generally "v" shaped.

12. The process of Claim 1 wherein the compressed admixed tobacco material provided by passing the tobacco material through the first pressurized roller system is contacted with tobacco dust and/or tobacco fines prior to passing the compressed, admixed material through the second pressurized roller system.

13. The process of Claim 1 wherein each of said grooves circumscribe the roller substantially transversely relative to the longitudinal axis of the roller.

14. An apparatus for providing reclaimed tobacco, the apparatus comprising (a) a first pressurized roller system wherein at least one of the roller faces thereof comprises a series of grooves, said series extending longitudinally along the roller wherein each groove extends about the periphery of the roller, and wherein each groove has a maximum width near the surface of the roller and a minimum width near the bottom of the groove, (b) a second pressurized roller system wherein the roller faces of the rollers are positioned in a spaced apart relationship in a region along the rollers, and wherein the spaced apart relationship between the faces of the rollers is a distance which approximates the thickness of sheet-like reclaimed tobacco material.

15. The apparatus of Claim 14 wherein each groove has a depth which ranges from about 0.015 inch to about 0.035 inch.

T-161:38

16. The apparatus of Claim 14 wherein each groove has a greatest width which ranges from about 0.015 inch to about 0.040 inch.

17. The apparatus of Claim 14 wherein each groove has a flattened or rounded bottom.

18. The apparatus of Claim 14 wherein each groove circumscribes the roller substantially transversely relative to the longitudinal axis of the roller.

19. The apparatus of Claim 14 wherein the spaced apart relationship is provided by a groove which extends along a portion of the longitudinal length of one of the rollers of the second pressurized roller system.

20. The apparatus of Claim 14 wherein the spaced apart relationship is provided by idler bearings and spacer rings which circumscribe each end of a roller of the second pressurized roller system.

21. The apparatus of Claim 14 wherein the spaced apart relationship is a distance from about 0.002 to about 0.020 inch.

22. The apparatus of Claim 20 wherein the rollers forming the second pressurized roller system are rotated at differing speeds during use thereof.

23. The apparatus of Claim 14 wherein the spaced apart relationship is provided by idler bearings and spacer rings which circumscribe each end of a roller of the first pressurized roller system.

24. The apparatus of Claim 23 wherein the rollers forming the first pressurized roller system are rotated differing speeds during use thereof.

25. The apparatus of Claim 14 wherein one roller is common to each of the first pressurized roller system and the second pressurized roller system.

T-161:39

26. The apparatus of Claim 14 which provides sheet-like reclaimed tobacco material which is about 2 inches in width.

27. A process for providing reclaimed tobacco material in sheet-like form, said process comprising the steps in combination (a) providing tobacco material including tobacco leaf stem material, the tobacco material having a moisture content less than about 30 weight percent, and then (b) passing the tobacco material through the nip of a pressurized roller system having two rollers exhibiting a nip zone pressure sufficient to provide compression of said tobacco material thereby providing said sheet-like material, wherein (i) at least one of the roller faces comprises a series of grooves, which series extends longitudinally along the roller and each groove extends about the periphery of the roller, wherein each groove has a maximum width near the surface of the roller and a minimum width near the bottom of the groove, wherein each of the grooves has a maximum width and depth which is smaller than the length and/or diameter of tobacco leaf stem material, and wherein the tobacco leaf stem material is employed in a structured strength providing amount and (ii) wherein the roller faces of the rollers are in a spaced apart relationship in the region along the rollers where the reclaimed tobacco material is formed and wherein the spaced apart relationship between the faces of the rollers provides a sufficient distance therebetween to provide formed sheet-like reclaimed tobacco material.

T-161:40

28. The process of Claim 27 wherein said of tobacco material is provided in the absence of a binder.

29. The process of Claim 27 wherein the amount of said tobacco leaf stem material in said tobacco material is at least about 15 percent, based on the total weight of said tobacco material.

30. The process of Claim 27 wherein said nip zone pressure is at least about 3,000 pounds per linear inch.

31. The process of Claim 27 wherein the tobacco material exhibits a moisture content between about 15 weight percent and about 18 weight percent.

32. The process of Claim 27 wherein the tobacco material exhibits a moisture content between about 14 weight percent and about, 25 weight percent.

33. The process of Claim 27 wherein the amount of said structural strength providing amount of leaf stem material ranges from about 15 to about 18 percent based on the total weight of tobacco material which is employed.

34. The process of Claim 27 wherein each of said grooves is generally "V" shaped.

35. The process of Claim 27 wherein each of said grooves circumscribe the roller substantially transversely relative to the longitudinal axis of the roller.

36. An apparatus for providing reclaimed tobacco, the apparatus comprising (a) a pressurized roller system wherein at least one of the roller faces comprises a series of grooves, which series extends longitudinally along the roller and each groove extends about the periphery of the roller, wherein each groove has a maximum width near the surface of the roller and a minimum width near the T-161:41 bottom of the groove, wherein each of the grooves has a maximum width and depth which is smaller than the length and/or diameter of tobacco leaf step material, and wherein the roller faces of the rollers are in a spaced apart relationship in a region along the rollers where the reclaimed tobacco material, is formed and wherein the spaced apart relationship between the faces of the rollers is a distance which approximates the thickness of sheet-like reclaimed tobacco material.

37. The apparatus of Claim 36 wherein each groove has a depth which ranges from about 0.015 inch to about 0.035 inch.

38. The apparatus of Claim 36 wherein each groove has a greatest width which ranges from about 0.01 inch to about 0.040 inch.

39. The apparatus of Claim 36 wherein each groove circumscribes the roller substantially transversely relative to the longitudinal axis of the roller.

40. The apparatus of Claim 36 wherein the spaced apart relationship is provided by a groove which extends along a portion of the longitudinal length of one of the rollers of the second pressurized roller system.

41. The apparatus of Claim 36 wherein the spaced apart relationship is provided by idler bearings and spacer rings which circumscribe each end of a roller of the second pressurized roller system.

42. The apparatus of Claim 41 wherein one of the rollers has a substantially smooth surface.
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